Achieving Operational Efficiency by Leveraging PI System ...

© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015

Presented by

Achieving Operational Efficiency by Leveraging PI System at PowerStream

Vince Polsoni, PowerStream Inc.


Where are we?

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Ontario 1,068,587 km2

Texas 696,200 km2

Powerstream Service Territory • 806 km2 • 11 Municipalities • Located just North of Toronto

Powerstream Service Territory


PowerStream Fast Facts

• 2nd Largest Municipally owned Local Distribution Co. (LDC) in Ontario, Canada

• Serving 11 Communities through Central Ontario (Serving over 1 million residents)

• 550 Employees

• 343,000 Customers : (Residential (89%) Commercial Ind. (11%) )

• Total Revenue: $788 Million

• Total Assets: $1,087.5 Million

• Overhead Circuit Wires: 2,500 km

• Underground Cable: 4,900 km

• Transformer Stations (TS’s): 11

• Municipal Substations (MS’s): 55

• Distribution Transformers: 43,000

• Switchgears: 1,800

• Poles: 40,000

• Peak Demand: 1,972 MW

• Geographical Size of Service Territory: 806 Sq. Km

• Distribution Voltages 4kV, 8kV, 13.8kV, 27.6kV and 44kV

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Agenda

• PI System in use at PowerStream (Operations)

• Technology and Innovation

– Equipment Monitoring

– Big Saves

– PI System Dashboards

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Life before PI System / Operations Reporting SCADA / CMMS / OMS / CIS / ERP / EAM / WFM

SCADA

• Data is overwritten based on frequency of data point collection in some databases (e.g. SCADA)

• Archived/Historical data is often extracted and stored in flat files (spreadsheets)

Reports Data Dumps

OMS CIS

CMMS

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Station Maintenance at PowerStream

– RCM2 methodology incorporated into CMMS

– Risk based Condition Based Maintenance (PI System and CMMS)

– Instant Information (true real-time)

• Instant Notifications from PI System (Real-time)

• Alerts from Computerized Maintenance Management System (CMMS) (CASCADE)

• Better Reporting and Asset Health assessments

– Automatic Maintenance Work Orders triggered by Events in SCADA via PI System and Maintenance/Inspection Reads

– Field staff aware of equipment condition/health/risk

– One data source

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Background - PI System at Powerstream

• July 2012

– Implementation – 5000 tags, PI ProcessBook, PI DataLink

– Justified as part of Computerized Maintenance Management System (CMMS) implementation strategy

• 2013 to 2014

– Operational reports (PI ProcessBook, PI Coresight, DataLink, PI WebParts)

– Asset Framework (AF), Templates

– Notifications

– 30,000 tags

• 2015

– Performance Equations, Data sets, Analysis, Tables

– Dashboards (PI Coresight and PI WebParts)

– PI Interfaces (CMMS, OMS, HTML, UFL)

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Leveraging PI System at Powerstream

• Operations Dashboards (Public Monitors, IPAD)

• Link to multiple databases/systems

– SCADA, OMS/CIS, CMMS, MicroGrid

– PI HTML Interface, PI UFL Interface

– Expand Notifications / Alerting to stakeholders (email) • Offload low level SCADA alarms through PI System

Notifications to field staff (awareness)

• AF, Performance Equations and Asset Analytics

• Next – ESRI Integrator, Forecasting, Enhanced Analytics

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Station Sustainment Innovation Equipment Monitoring – SEL Relays

– Online Transformer Gas in Oil Monitoring Units

• (7 Gas) DGA monitors on 55/83 MVA and 75/125 MVA transformers

• Hydrogen monitors on 5 to 20 MVA transformers

– Portable DGA testers

– Tap Changer Filtration Systems. Transformer Oil Dry-out Filtration System

– Online Bushing Monitoring Systems

– Maintenance Free Dehydrating Breathers

– Station Equipment Temperature Sensors (new 2015)

https://www.google.ca/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCOv-oPTZjcgCFRWOkgod9xsEYw&url=https://www.leadingedgesales.ca/product/g3-britespot-thermal-monitor-bs3g-9s/&psig=AFQjCNFtfJs1p5W3ddvBu61X069Gr-5Zmg&ust=1443116429742204


PI System Products used at Powerstream

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• PI ProcessBook • PI Coresight • PI WebParts • PI DataLink • PI AF • PI SMT, PI Explorer, PI ICU • PI HTML Interface • PI UFL Interface • PI RDBMS Interface • Templates

• Element • Notifications

30,000 tags

(and growing)


PI System Explorer – AF - PowerStream

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Elements Notification Templates Element Templates Notifications


How PowerStream uses PI System Explorer

• Asset Framework

• Elements

– Attributes from PI Points, CMMS, OMS, web pages(HTML) and static data

– Create tags from attributes using “Analyses” tab

– Attributes used in many PI System Reports

• Library

– Notification Templates

– Tables (from OMS, CMMS)

• Notifications

– Over 1400 notifications enabled

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• Automatically Generate maintenance task in CMMS system based on triggers, gather data from OMS

• Basic functions (average, max, min) • Trends, calculated values, counters

• Various displays catering to different audiences • Various display tools • Drill–down user interface

• Notifications and alarms (Real-time) • Access to Reports via Notifications

Leveraging PI System for Risk Based Condition Based Maintenance

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Real-time Alerting

Visual Reports

User Friendly

Simple Tools

Integration


Condition Based Maintenance - Data Flow

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SCADA PI

System CMMS

Station Equipment Analog & Status Data

CMMS Alerts (delayed)

PI Notifications (Real-time)

Firewall

PI System Reports / Dashboards (Real-time)

CMMS Work Order

Firewall

Patrols

HTML

Internet Scraping

Reads

OMS

(CMMS)

Algorithm Rules Engine

Outage Mgmt System


SCADA – PI System – CMMS working as One

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(from SCADA event) (from CMMS) (automatically generated)

PI Notifications CMMS Alert CMMS Work Order

PI System Report PI System Report

High

(High Water Alarm Cleared) (High Water Alarm)


PI ProcessBook Reports - Powerstream

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• System Demand • Geomagnetic Induced Current • Station Performance/Risk • DC System • Station Fire Alarm • Building Heating • Station Single Line Diagrams • Primary Switch Status • Under Frequency Load Shed

• Transformer • Condition (Health) • Dissolved Gas Analysis • Oil Temperature & Cooling • Tap Changer and Tap

Changer Position • Bushing Monitoring • Hydrogen Gas

• Circuit Breaker

• Status and Detailed • SF6 Status


PI ProcessBook Reports Home Page

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PI ProcessBook – TS Transformer Report

Links: • Weather report • Radar Map Link

Pictures External Database/App

Trends

Animations

Gauges

Equipment Attributes

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AF Elements

Template Report

Status


Station Performance/Risk Reports

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Transformer Station

Performance (Risk)

Distribution Station

Performance (Risk)


Geomagnetically Induced Current Report

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Transformer Online Bushing Report

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Corporate / Operations Dashboards

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© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015 23

System Loading Dashboard


230kV Transmission Supply Status Report

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Regional Demand: Current, 30 Day & Year to Date Maximums

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Current Outages By Region

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System Reliability Report using PI Coresight/PI ProcessBook

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Substation Interconnection – Load Transfer Report

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TS Transformer Criticality, Health and Risk Report

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Substation Distribution Transformer Hydrogen Gas Alarm Report

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PI ProcessBook Reports

Tap Changer

DC Systems

230 kV Primary Switch Status

Circuit Breaker Status

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Demand Report • Use PI System to view and notify when System Demand approaches

Powerstream’s “All-Time” peak.

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PI ProcessBook – Station Single Line

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Notifications

• Low SF6 Gas

• Current Total Outages by Region

• Station Building Temp

• DC System

• Battery Low Voltage

• Calisto 9 General Alarm

• Circuit Breaker Operation

• Transformer Online / Offline

• Transformer Oil Temp/Cooling

• Tap Changer Oil Filtration Alarm

• Feeder Protection Trip

• Secondary Breaker Operation

• Primary Switch Operation

• High Sump Water Level

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Outage Information Flow with PI System

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Notifications Feeder Protection Trip

Link to view PI Coresight Report

Notifications Outage Counts by Region

Email from Outage Management System


PI Coresight Report – System MW

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PI Coresight – Transformer Reports

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Transformer Load (MW) Transformer Hydrogen and Moisture

Transformer Winding Temperature


Big Saves - Thanks to PI System

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Save - 10MVA 44kV-13.8 kV Transformer

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Notifications • Hi Winding Temperature • Hi Hydrogen Alarm

Installed a Hydrogen Gas Monitoring Unit and connected to SCADA (PI)

• $500,000 averted • No customer outages • Transformer taken out of

service before failure and replaced with spare


Save - 75/125 MVA 230kV-27.6kV

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Transformer - Save

• In late 2011 noticed increased gassing from annual oil test results from laboratory.

• In early 2012 Purchased a portable DGA unit and began to test and monitor transformer oil.

• In summer 2012 implemented PI System. • In fall 2012 installed a 7 gas oil monitoring unit created tags in

PI Data Archive • Created PI Report and configured a Trigger in CMMS to monitor

gassing vs. load and oil temperature • Consulted with transformer SME’s (provided SME’s PI Server data)

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Comparison T3 and T4 DGA Trends

T3 (Good) T4 (Failing)

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E:/GreenwoodT4.mov


Expert Systems Working in Unison

Oil Oil

Data Data

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Data Analysis Analysis


Increased Gassing - 2 Significant Events

Oct 20, 2012 April 19, 2013

PI Coresight PI Coresight

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Gassing in Transformer

PI ProcessBook, TOA4 and CASCADE CMMS

TOA4

CMMS

PI Processbook

Transformer Problem Identified

(Health and Risk)

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Daily or

on demand

daily


Findings

• It was found that one of the "T" connectors was not crimped during manufacturing to the copper lead.

Repair: $100,000 (Potential Failure)

Up to $2 million if unit failed catastrophically or with serious internal damage to windings or core.

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E:/GreenwoodT4.mov


Expansion of PI System at PowerStream

• Corporate and Operations Dashboards

• Micro Grid Reporting

– Micro Grid Demonstration Project (PowerStream head office)

– Penetanguishene Micro Grid Project –PowerStream / KEPCO (Penetanguishene, ON, Canada)

• ESRI Integrator – GIS

• Analytics

• Potential Merger (more opportunities)

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Benefits of PI System

• Maintenance Optimization

• Able to accomplish a lot with minimal resources

– Fast learning curve

• YouTube, Manuals, Support, Training

• Innovation stimulant

• Instant Information to those who need it

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PowerStream’s Micro Grid Projects

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• Micro Grids work in the same way as large-scale electricity delivery systems or the grid, but instead of delivering electricity to hundreds of thousands or millions of customers at a time, they can be scaled down and customized to meet the needs of communities or even just one customer.

• Micro Grids rely on a mix of clean and renewable sources of generation and can operate independently or feed electricity back to the grid.


Micro Grid Demonstration Project

• Launched the Micro Grid demonstration project in November 2013 at its head office in Vaughan, Ontario.

• Using the project to evaluate a Micro Grid’s performance while it is connected to, and also disconnected from, the provincial grid.

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• 30 kW load

Display and analysis

• 25 kW Renewables • Solar • Wind

• 35 kW Natural Gas Generator

• 40 kWh storage • Batteries

• Lead Acid • Lithium • Na Ni CL


Generation Assets

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1.8 kW Wind Generator

17 kW Tracking Solar Generator 5 kW Solar

Generator (EV Car Port)

35 kW Natural Gas Generator


Control and Storage Assets

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Communications and Control System

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D400 Gateway Protocol Convertor

Smart Load Panel Transfer Switch

SCADA Server

PI ProcessBook, HMI Display Screens

PI Server

www.

Battery Systems EV Charger NG Generator

G

SMA Inverters

Modbus Ethernet

HDMI

Ethernet


PI ProcessBook Micro Grid Display

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• Multiple report options • Historical data • Mobility (Smartphone, tablet)

• Notifications and alarms (Real-time)

• Intuitive Display • Various displays catering to different audiences • Drilldown user interface

PI System Benefits – Micro Grid Project

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Real-Time Display

Notifications / Alarms

User Friendly

Simple Tools


Penetanguishene Micro Grid – PowerStream / KEPCO Project (2016)

• Partnership between PowerStream and Korea Electric Power Corporation (KEPCO) • Installed adjacent to one of PowerStream’s Municipal Substations • Operated from PowerStream’s System Control Centre with remote monitoring using

PI System for PowerStream • Provides power to customers even when there is a loss of supply from the provincial

grid • Connected to PowerStream’s distribution feeder that provides up to 11 hours of

backup power for approximately 400 customers in Penetanguishene, ON, Canada. • Micro Grid will operate either connected to the grid (grid mode) or disconnected

from the grid (island mode) • Comprised of

– Two 500 kilowatt-hours (kWh) batteries – One 750 kilowatt power control system

• Construction underway - 2016 implementation

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http://www.penetanguishene.ca/en/index.asp


RESULTS AND BENEFITS BUSINESS CHALLENGES SOLUTION

Summary

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A. Optimize Maintenance practices and improve system reliability

B. Provide and utilize Operational data outside of SCADA (Operations)

C. Build Operations Dashboards and expand the use of PI System

A. SCADA to PI connectivity

B. Integrated PI System to CMMS and OMS

C. Utilize PI Notifications to alert on potential failures

D. Build Dashboards

• Real-time information to those who need it

• Increased equipment monitoring and alerting

• Information is current and consistent

• Improved Reliability and Availability

There is a constant pressure to do more with less. Improve reliability and availability. In order to achieve this, the same information needs to be made available in multiple systems.

Data turned into Information is the key to achieving Operational efficiency.


Contact Information

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Vince Polsoni

[email protected]

Manager Station Sustainment

PowerStream Inc.

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